The µ-Revolution project, “Micronisation Revolution: AI-Driven Material and Process Development for Cross-Market Solutions,” seeks to redefine additive manufacturing (AM) by addressing critical challenges in material cost, process scalability, and sustainability. The focus is on developing an innovative production chain for PA12 powders, a key material for Selective Laser Sintering (SLS), which enables the efficient production of complex plastic components. At its core, the project aims to replace traditional cryo-milling with a novel micronisation technology. This process not only reduces energy consumption but also ensures consistent, high-quality powders with improved flowability and homogeneity. PA12 powders will be optimized for SLS and related powder markets, such as metal coating, while the price-reduced granulate can be further used for injection molding. By leveraging economies of scale through cross-market multplication, and introducing cost-efficient production methods, makes these materials accessible for widespread industrial use. Additionally, the project aims to increase the recyclability of SLS powders to nearly 100%, significantly reducing material waste, and used parts will be re-introduced to the micronisation process to promote a circular economy. The integration of advanced machine learning (ML) algorithms is a key innovation. ML models will enhance polymer synthesis by improving reactor efficiency, optimizing production times and reducing costs. In micronisation, ML will accelerate the identification of optimal powder formulation & SLS process parameters to ensure consistent mechanical properties and minimize waste. These data-driven approaches will shorten development cycles, lower costs, and enable precise process control, making SLS a more viable alternative to traditional manufacturing methods. For further market multiplication, the findings of the ML and miconisation process will be tested against an additional polymer. Sustainability is embedded in the project through a cradle-to-cradle life cycle assessment (LCA) approach. This methodology will evaluate the environmental impact of every step in the production chain, guiding targeted optimizations to reduce CO₂ emissions and material waste. The project’s focus on recyclability, energy efficiency, and material savings positions it as a benchmark for sustainable manufacturing in Europe and beyond. The µ-Revolution consortium brings together industry leaders and research institutions to ensure comprehensive expertise. EMS-Chemie (Switzerland) will focus on AI-driven polymer synthesis, while Lean Plastics Technologies (Germany) will advance their innovative micronisation technology. Inspire AG (Switzerland) will contribute ML integration and additive optimization, and Neue Materialien Bayreuth (Germany) will lead SLS process validation, LCA execution, and industrial-scale testing. This collaboration ensures a seamless transition from research to industrial application. By combining advanced technology with sustainable practices, µ-Revolution will deliver cost-effective, high-performance materials tailored for SLS and related applications. The project will establish new standards for material efficiency, recyclability, and environmental impact, setting the stage for a transformative shift in additive manufacturing and cross-market solutions.